User Manual

Hydraulic assembly tool

Type HE; HF; HS; NE; NH; NS; NT; HC
for LOKRING® tube connections
Table of contents

Table of contents ......................................................................................................................... 2

1 About this user manual ................................................................................................... 4

1.1 Explanation of symbols ...................................................................................................... 4
1.2 Limitation of liability............................................................................................................ 5
1.3 Scope of delivery ............................................................................................................... 5
1.4 Warranty terms .................................................................................................................. 5
1.5 Manufacturer ..................................................................................................................... 6

2 Safety ................................................................................................................................ 6
2.1 Intended use ...................................................................................................................... 6
2.2 Misuse ............................................................................................................................... 6
2.3 Safety notices and accident prevention ............................................................................. 6
2.3.1 General .............................................................................................................................. 6
2.3.2 Operating personnel .......................................................................................................... 6
2.3.3 Work area .......................................................................................................................... 7
2.3.4 Residual risks and safety measures .................................................................................. 7

3 Description of product .................................................................................................. 10

3.1 Designation...................................................................................................................... 11
3.2 Models HE and NE .......................................................................................................... 11
3.3 Models HF, HS, NF, NS and NT ...................................................................................... 11
3.4 Technical data ................................................................................................................. 13
3.5 Operating conditions ........................................................................................................ 13

4 First start-up .................................................................................................................. 13

4.1 Connecting the tool .......................................................................................................... 13
4.2 Before first use ................................................................................................................ 13

5 Use .................................................................................................................................. 14
5.1 Operating principle........................................................................................................... 14
5.2 Assembly of a LOKRING tube connection ....................................................................... 15

6 Adjustment of the assembly tool ................................................................................. 18

7 Storage and transport ................................................................................................... 28

8 Maintenance and care ................................................................................................... 29

8.1 Cleaning .......................................................................................................................... 30
8.2 Lubrication ....................................................................................................................... 30

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9 Troubleshooting ............................................................................................................ 32

10 Disposal.......................................................................................................................... 32

Appendix A: Declaration of conformity.................................................................................... 33

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1 About this user manual
IMPORTANT!
Read the user manual carefully before using the machine and keep in a safe place for the
life of the product!
Also read and observe the user manual for the LOKRING® hydraulic aggregate for gener-
ating the required working pressure!
This user manual is part of the product. Illustrations in this manual are provided for general understanding and
can differ from the actual model. It is assumed that personnel are familiar with normal procedures such as the
use of suitable work clothing (e.g. work shoes, hearing protection, safety goggles, etc.). Subject to technical
modifications. In addition to carefully reading the user manual, we also recommend that you obtain training and
instruction in operation and handling of assembly tools from one of our qualified technicians. In case anything
is unclear, please contact the manufacturer.

1.1 Explanation of symbols

Safety notices in this manual are marked with symbols. The safety notices are introduced with signal words
that express the scope of the hazard. Always comply with safety notices and act with caution in order to pre-
vent accidents, personal injury and material damage.
DANGER!
indicates a hazard with a high degree of risk, which if not avoided will result in death or
severe injury.

WARNING!
indicates a hazard with a moderate degree of risk, which if not avoided can result in death
or severe injury.

CAUTION!
indicates a hazard with a low degree of risk, which if not avoided can result in minor or
moderate injury.

INFORMATION!
indicates special information for effective handling of the tool.

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1.2 Limitation of liability
All information and notices in this manual were compiled taking into account the applicable standards and regu-
lations, in accordance with the state of the art, as well as our extensive knowledge and experience.
The manufacturer assumes no liability for damages arising from:

 Failure to observe the user manual

 Non-intended use
 Deployment of untrained personnel
 Unauthorized modifications
 Technical changes
 Use of non-approved spare parts
Use of the assembly tool in violation of regulations or unauthorized modifications to the machine will exempt
the manufacturer from liability and will invalidate the declaration of conformity! In this case the user will be lia-
ble for damages resulting from use of the machine.
In the case of special versions, the ordering of additional options, or on the basis of the latest technical chang-
es, the actual scope of delivery can deviate from the explanations and depictions described in this manual.
The following documents and/or regulations apply: the obligations stipulated in the delivery contract, the Gen-
eral Terms and Conditions and the manufacturer’s Terms of Delivery, and the applicable statutory regulations
at the time the contract is concluded.

1.3 Scope of delivery

The scope of delivery includes:

 1 x hydraulic assembly tool

 1 x user manual

1.4 Warranty terms

The warranty terms are included in the manufacturer's terms and conditions.

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1.5 Manufacturer
The manufacturer of the hydraulic assembly tool is:
VULKAN Lokring Rohrverbindungen GmbH & Co. KG
Heerstrasse 66
D-44653 Herne
Tel.: +49 2325-922-155
Fax: +49 2325 51222
E-mail: info.Lok@vulkan.com

2 Safety

2.1 Intended use

This assembly tool is intended only for commercial use with hydraulic aggregates from VULKAN Lokring
Rohrverbindungen GmbH & Co. KG in accordance with the descriptions and safety information provided in this
user manual. Operation of the assembly tool is permitted only indoors.

2.2 Misuse
Any use of the product that deviates from the intended use is deemed misuse. Use of the machine with other
hydraulic aggregates, in particular those of other manufacturers, is prohibited.

2.3 Safety notices and accident prevention

2.3.1 General
The instruction in this user manual and the safety notices affixed to the unit with respect to operation, mainte-
nance and repairs must be observed and complied with for safety reasons.

2.3.2 Operating personnel

The use of tools can involve certain risks. Their operation and handling is therefore permitted by trained and
experienced personnel only. First startup, maintenance and repairs must be carried out by specially trained
personnel. Take advantage of the training measures offered by the manufacturer.
Operating personnel must wear close-fitting clothing and safety shoes. The minimum age for operation of the
tool is 18. However, it is permitted to allow persons age 16 and older to work with the tool if required for com-
pletion of an apprenticeship, under the supervision of a competent professional.

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2.3.3 Work area
In order to ensure safe working conditions it is absolutely necessary that the work area be level and hard-
wearing, and that there is sufficient space for freedom of movement. The workplace must also be sufficiently
illuminated.

2.3.4 Residual risks and safety measures

It is strictly prohibited to disable, modify, block, remove, convert or supplement any components of safety and
protective devices of the hydraulic tool; failure to comply can result in defects and/or life-threatening injuries.
The manufacturer cannot be held liable for damage or injuries resulting from such negligence. Any instances of
negligence mentioned above will also immediately void any warranty entitlement.

CAUTION!
Danger of injury!
From unpacking, lifting or transport of the assembly tool
Minor injuries can result
Wear suitable safety shoes when unpacking, lifting or transporting the assembly tool!

DANGER!
Danger of injury!
Slipping, stumbling and falling
Severe injuries will result
Watch out for surfaces that have become slippery from use of the machine and also for
tripping hazards caused by the hydraulic hose.

DANGER!
Danger of injury!
From inadvertent startup of the machine
Severe injuries will result

Do not connect or disconnect tools to/from the hydraulic aggregate while the unit is con-
nected to the electric power grid. Inadvertent startup of the hydraulic aggregate can
cause serious injuries.
Unplug the plug!

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 DANGER!
Danger of injury!
Due to contact with hot surfaces
Severe injuries can result
Some parts of the hydraulic aggregate become very hot during operation. To avoid
burns, do not touch hot machine parts.

DANGER!
Danger of injury!
From closing jaws
Severe injuries will result

 Do not reach into the danger zone between the assembly jaws!
 This also applies in the event that the tool cannot be removed from the tube after
assembly, because the tube is jammed in the tool. In this case first pull the plug
and then release the tool manually.
 Loose-fitting clothing, jewelry or long hair can be caught. It is also possible that
certain types of gloves can be caught. Therefore, wear only tight-fitting clothing
and no jewelry, and always ensure that hair is protected!

DANGER!
Danger of injury!
Due to explosion
Severe injuries will result
Use of the tool in explosive areas is not permitted.

WARNING!
Danger of injury!
Severe injuries will result
When working on the hydraulic assembly tool and when connecting the tool to the hy-
draulic aggregate, always comply with the applicable safety regulations, especially the
accident prevention regulations of the trade associations.

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 WARNING!
Danger of injury!
Severe injuries will result
Always disconnect hydraulic hoses from the hydraulic aggregate when no assembly tool
is connected!

WARNING!
Danger of injury
Severe injuries will result
If there are indications of irregular function and performance, stop using the tool immedi-
ately and service or repair the tool!

CAUTION!
Danger of injury
Minor injuries will result
When handling the tool, be aware of the danger that can arise from uncontrolled move-
ments of pressurized hoses. For example, separation of the hydraulic hose from the tool.
Conduct daily inspections of hydraulic hoses and hydraulic connections for damage or
wear, and replace if necessary.

CAUTION!
Danger of injury
Minor injuries will result
Never exceed the maximum operating pressure of 300 bar. Otherwise, this can result in
destruction of the assembly tool and danger to other people.

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3 Description of product
The hydraulic assembly tool is used only for assembly of LOKRING tube connections on tubes intended for this
purpose. The required working pressure is generated by a hydraulic aggregate, which is also available from
VULKAN Lokring.

Figure 1
a. Start button
b. Jaw constant
c. Jaw variable
d. Clamping jaws
e. Control pin
f. Protective plate
g. Jaw housing

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3.1 Designation
The name of the assembly tool is composed of the following properties:
HAT-A-BB-CC,CC-LRDD+EE-XF (Example: HAT-L-HE-03,00-LR07-10)
HAT: Hydraulic Assembly Tool
A: Tool size (S, M, ML, L, XL or XXL)
BB: Model (based on clamping jaws)

CC,CC: Clamping jaw size

LRDD: Outer diameter of the LOKRING tube connection
EE: Recess of the jaw constant for the LOKRING tube connection
XF: Special tool

3.2 Models HE and NE

The HE and NE tools are for tube connections in which the outer tube is flared. The clamping jaws (d) are
smooth and engage behind the flared area. When the tool closes, they slide over the non-flared area until they
press against the flared area. This stabilizes the flared area.

3.3 Models HF, HS, NF, NS and NT

These models are for tube connections in which the fixed clamping jaw has to clamp on the outer tube. The
outer tube is not flared or is only slightly flared. In this models the overlapping of the LOKRING tube connection
can be adjusted.

Figure 29

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The following table shows the information on the type plates of the assembly tools:
VULKAN Lokring
MANUFACTURER Rohrverbindungen GmbH & Co. KG
Heerstraße 66
(Manufacturer) DE-44653 Herne, Germany
www.vulkan.com
TYPE
HAT
(Type)

BUILT
YYYY
(Year of manufacture)

PMAX
300 bar / 30 MPa
(Rated pressure)

Qnominal
2.5 l/min.
(Flow rate)

DOCUMENT
HAT-UM-U1-V1.0
(Drawing no. of documentation)

SERIAL NO. HAT-YY-XXX

(Serial number) (YY = year of manufacture / XXX = serial number)

Table 1

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3.4 Technical data
Max. outer diameter of tube: 28 mm*
Max. tube wall thickness: 1.5 mm*
Max. operating pressure: 300 bar
Assembly time: approx. 2 sec.
A-weighted sound pressure level LpA:** 75.8 dB (expanded uncertainty U = +3 dB)

Total vibration value: 1.93 m/s² (expanded uncertainty U = 1.14 m/s²)

Weight: approx. 3 kg
Dimensions: approx. 315 x 80 x 50 mm
*other dimensions on request

**with VULKAN Lokring hydraulic aggregate model HA

3.5 Operating conditions

Permissible ambient temperature: 0°C to 40°C
Permissible relative humidity: ≤ 90% (non condensing)

4 First start-up

4.1 Connecting the tool

Remove packaging and check tool for damage. Before connecting the tool, check to ensure that threaded joints
are firmly seated and the tool guides are smooth running. If necessary, lubricate the guides with a universal
lubricating spray. Connect the assembly tool to the hydraulic hoses of the VULKAN Lokring hydraulic aggre-
gate (Attention: Switch off hydraulic aggregate!). For correct connection, refer to the user manual for the hy-
draulic aggregate.

4.2 Before first use

To ensure that the assembly tool is functioning properly, after correctly connecting the assembly tool to the
hydraulic aggregate, press the start button (a) several times, without assembling a tube connection.

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5 Use
Conduct the following inspection before use:
Assume a stable position and hold the tool correctly: Be ready to counteract normal or sudden movements.
Check tool for possible damage prior to use.

WARNING!
Danger of injury
Severe injuries will result
If there are indications of irregular function and performance, stop using the tool immedi-
ately and service or repair the tool!

INFORMATION!
The operating pressures on the hydraulic aggregate are set at the factory and should not
be changed.

INFORMATION!
The following description is based on the assembly of a LOKRING® tube connection with
a flared outer tube. There are different connection types for LOKRING ® tube connec-
tions, and therefore different tube geometries. Always consult the Best Practice docu-
ment for the application.

5.1 Operating principle

Press and hold the start button (a) on the tool to activate the motor of the hydraulic aggregate so that the pump
generates the set pressure. The tool is activated by the hydraulic pressure. Once the set pressure is reached
and the work process of the tool is completed, the hydraulic aggregate is deactivated. If the start button (a) is
released during operation, the hydraulic aggregate is deactivated and the tool returns to starting position.

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5.2 Assembly of a LOKRING tube connection
DANGER!
Danger of injury!
From closing jaws
Severe injuries will result

 Do not reach into the danger zone between the assembly jaws!
 This also applies in the event that the tool cannot be removed from the tube after
assembly, because the tube is jammed in the tool. In this case first pull the plug
and then release the tool manually.
 Loose-fitting clothing, jewelry or long hair can be caught. It is also possible that
certain types of gloves can be caught. Therefore, wear only tight-fitting clothing
and no jewelry, and always ensure that hair is protected!

Proceed as follows to assemble the LOKRING tube connection:

1. Assembly direction
Push the LOKRING onto the inner tube, with the end having the Smallest
Chamfer
diameter
smallest diameter first.

2. Place the LOKRING on the inner tube

Place the LOKRING with the chamfer on the inner tube in the
Chamfer
assembly direction.

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3. Push the LOKRING onto the inner tube
Push the LOKRING onto the inner tube.

4. Insert inner tube

Push tubes at least the length of the LOKRING + 3 mm, or in the

case of flared tubes, all the way to the stop.

5. Apply LOKPREP
> Always use the included pipettes to apply LOKPREP.
MIN 120°
> Apply LOKPREP at least in an area of 120° of the tube cir-
cumference.
> Capillary action ensures the even distribution of LOKPREP.

6. Position the LOKRING

Push the LOKRING in the direction of the outer tube until the
chamfer touches the outer tube.

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7. Position the tool
Position the assembly tool at a slight angle so that the LOKRING
is firmly in the jaw constant (b).

8. Clamp outer tube

> Press the outer tube against the clamping jaws (d) until the
tube locks into place; in the case of a flared tube, clamp be-
hind the flared area.
> Align the assembly tool perpendicular to the connection.

9. Check the position of the LOKRING

> The LOKRING must be flush within the jaw constant (b).
> The LOKRING must be in contact with the outer tube.

10. Check tubes

Make sure that the inner tube is inserted far enough into the outer
tube; in case of flared tubes, all the way to the stop.

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 11. Carry out assembly
> Press and hold the start button (a) on the assembly tool until
assembly is complete.
> Afterwards, the assembly tool opens automatically.

12. Done

> The outer tube must be visible at least 1 mm and in the full
MIN. 1 mm, 360°
circumference behind the smallest inner diameter of the LO-
KRING.
> The LOKRING must never be mounted beyond the end of
the flared area.

6 Adjustment of the assembly tool

For models HE and NE, adjustment of the assembly tool is not possible. If the LOKRING is pushed too short or
too far over the outer tube, check the length of the flared area of the outer tube for compliance with the applica-
tion drawing. If the LOKRING is still not correctly pushed on, contact the customer service department.
For all other models, adjustment of the overlapping length is possible.

The assembly tools are pre-adjusted for standard connections at the factory. Depending on the connection, it
may be necessary to readjust the assembly tool. To adjust the hydraulic assembly tools so that the ring is
pushed far enough over the outer tube, the control pin (e) must be adjusted accordingly. To facilitate adjust-
ment, the following theoretical formula can be used as a guide. However, readjustment of the control pin (e)
may still be necessary.

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A Tube connection B Jaw constant with control pin

Table 2

This formula can be used:

𝐿1 = 𝐿2 + 𝐿3 + 8 𝑚𝑚
L3 of 3 mm results in the following rule of thumb:

𝑳𝟏 = 𝑳𝟐 + 𝟏𝟏 𝒎𝒎

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Proceed as follows to adjust the control pin length:

1. Switch off the hydraulic aggregate

and disconnect the assembly tool
from the hydraulic hose.

2. Use a hexagon key to remove the

protective plate (f) from the tool.

3. Remove circlips from the jaw bolt of

the jaw constant (b).

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4. Remove the jaw bolt.

5. Remove the jaw constant (b) from

the tool.

6. Measure and note the length of the

control pin (e) L1.

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7. Loosen the setscrew that secures
the control pin (e).

8. Loosen the nut.

9. Unscrew the screw all the way.

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10. Adapt the length of the control pin
(e).

11. Drive out the control pin (e) with a

pin punch.

12. Check the control pin (e). If signs of

wear are visible on the cylindrical
surface, it must be replaced. Tap the
control pin (e) into the jaw constant
(b) to the desired length.
Note: If the LOKRING tube connection is
not pushed far enough over the outer
tube, the control pin (e) must protrude
out of the jaw constant (b) by the desired
length.

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13. Check the adjusted length.

14. Tighten the locking screw.

15. Carefully screw in the screw as far

as the control pin (e) and fix with the
lock nut.

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16. Insert the jaw constant (b) with the
guide pin into the jaw variable (c).

17. Align the holes in the jaw constant

(b) and the jaw housing (g).

18. Push Teflon washers on both sides

into the gap between the jaw con-
stant (b) and the jaw housing (g).

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19. Push the jaw bolt through the jaw
housing (g) and jaw constant (b).

20. Fasten circlips on the jaw bolt.

21. The jaw constant (b) is now mount-

ed. The distance between the jaw
constant (b) and the jaw variable (c)
still has to be adjusted.

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22. Loosen the nut and turn the screw in
or out to adjust the distance between
the jaw variable (c) and the jaw con-
stant (b).

Note: When the control pin (e) is just

before the clamping jaws (d), the dis-
tance between the jaws is correct. The
radius at the front of the control pin (e)
can be used for orientation. When the
run-out of the radius is still slightly visi-
ble, the tool is correctly adjusted.

23. Adjustment of the tool is complete.

24. Mount protective plate (f).

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 25. Connect the tool to the hydraulic
hose and conduct a test assembly.
Readjust the tool as necessary.

7 Storage and transport

Store the tool in the following conditions:

 Do not store outdoors

 Store in a dry and dust-free location
 Do not expose to aggressive media
 Protect from direct sunlight
 Avoid mechanical shocks
 Storage temperature: 15°C to 35°C
 Relative humidity: ≤ 60%
 When stored longer than 1 month:
o Preserve tool (lightly oil or grease metal parts) and wrap airtight in foil
o Check the general condition of all parts regularly
o If necessary, refresh or repeat the preservation
Clean all parts before storing the tool again.

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 8 Maintenance and care
The following sections describe the maintenance tasks that are necessary for optimal and trouble-free opera-
tion.

DANGER!
Danger of injury!
From inadvertent startup of the machine
Severe injuries can result
For cleaning, repairs and maintenance, and whenever leaving the workplace, de-
pressurize the tool and unplug the power plug from the power supply. It is not sufficient to
switch off the power by setting the switch to the OFF position.

If increased wear is detected as a result of regular inspections, shorten the required maintenance intervals
according to the actual signs of wear, and replace any defective parts (use only original VULKAN Lokring
replacement parts!).

Maintenance schedule:
after after after
daily weekly 20,000 40,000 120,000
assemblies assemblies assemblies
Cleaning and visual inspection X

Cleaning and lubrication of moving

X
parts near the screw head

Complete cleaning (dismantle all mov- at least

every 2
ing parts) months
Inspect and, if necessary, replace the
X X X
springs

Visual inspection of control pin (e) and

X X X X X
replace, if necessary

If you have any questions regarding maintenance tasks and intervals, please contact the customer service
department. If necessary, a general refurbishing can be arranged with the manufacturer.

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8.1 Cleaning
Periodic cleaning is necessary due to the ambient conditions and the use of the tool.
After extended use of the tool, LOKPREP can accumulate especially in the front area of the tool.
Remove LOKPREP manually. Wipe off any impurities with a lint-free cloth. To remove stubborn impurities,
LOKCLEAN (article no. L14004152) is recommended.
Never use solvents or acids, esters (organic compounds consisting of acids and alcohol), acetone (ketone),
chlorinated hydrocarbons or oils containing nitrocarbonates. Do not use chemicals with a low flash point.

8.2 Lubrication
Lubrication is very important and should be carried out carefully. Lubricate all pins, joints and springs, as well
as the piston movement, by hand only.
Lubrication of the piston is achieved by the hydraulic system.
Since lubrication is done manually, the tool should be inspected regularly. Also check the oil tank of the hydrau-
lic aggregate and add oil as necessary.
The following illustration shows the points that require special attention:

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9 Troubleshooting
No. Fault Remedy

Switch off hydraulic aggregate!

Carefully pull the tool out of the tube connection. If
blocked, use a hammer to carefully tap the guide pin
protruding from the jaw variable (c).
1 Tool jams or does not open
The tool will now open again. Check for possible
damage to components.
If the fault occurs again, contact the customer service
department.

For models HE and NE:

Check tube diameters, flared section is too short.
All other models:
LOKRING tube connection is not pushed on
2 1. Check the outer tube for slipping of the clamping
far enough.
jaws (d). Replace the clamping jaws (d) if neces-
sary.
2. Control pin (e) not set correctly. Set control pin (e)
again.

LOKRING tube connection is pushed on too For models HE and NE:

far. Check tube diameters, flared section is too long.
All other models:

Control pin (e) not set correctly. Set control pin (e)
again.

3 Oil drips from the front of the tool head. Seals are leaking. Contact customer service depart-
ment.

10 Disposal
Ensure compliance with the national regulations for recycling according to material type.
If no take-back or disposal agreement was made, dispose of the dismantled components by recycling. The
local authorities or specialized disposal companies can provide information on environmentally compatible
disposal. If necessary, the tool can be sent back to the manufacturer with a request for disposal.

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Appendix A: Declaration of conformity

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